Plant Head – Commercial Vehicle Components Manufacturing (20+ yrs exp)

Plant Head – CV Precision Components Plant

Location: Bhiwadi, Rajasthan

Department: Plant Operations & Commercial

Reporting To: Managing Director

Level: AGM / GM (Senior Leadership)

Position Overview

We are seeking an experienced Plant Head to lead the operational and commercial turnaround of a high-precision, export-oriented commercial vehicle (CV) components manufacturing plant.

This is a strategic transformation role rather than a steady-state plant management position. The successful candidate will work closely with the existing Production Head to improve operational efficiency, optimize costs, enhance quality, strengthen customer relationships, and restore sustainable profitability while ensuring uninterrupted customer deliveries.

The ideal candidate is a seasoned manufacturing leader with proven experience in plant turnarounds, operational transformation, and precision engineering within the automotive or industrial manufacturing sector.

Key Responsibilities

Operational Transformation

• Conduct a comprehensive assessment of plant operations to identify opportunities for productivity, cost, quality, and capacity improvements.
• Develop and execute a structured turnaround strategy with clear milestones and measurable outcomes.
• Ensure uninterrupted customer deliveries throughout the transformation period.
• Improve manufacturing efficiency using Lean Manufacturing, Theory of Constraints (TOC), and continuous improvement methodologies.
• Maximize utilization of installed production capacity.
• Strengthen shop-floor discipline through:
• 5S
• Visual Management
• Daily Management Systems
• Shift-wise performance accountability
• KPI-driven reviews

Manufacturing & Quality Excellence

• Partner with the Production Head to improve:
• Overall Equipment Effectiveness (OEE)
• Productivity
• Delivery performance
• Zero-defect manufacturing
• Lead Total Productive Maintenance (TPM) implementation across all TPM pillars.
• Drive a First Time Right (FTR) culture throughout manufacturing operations.
• Reduce customer PPM by implementing robust quality systems, root cause analysis, and corrective actions.
• Improve equipment reliability and preventive maintenance practices.

Cost Optimization

• Analyze the complete manufacturing cost structure, including fixed, variable, and avoidable costs.
• Drive sustainable cost reductions through:
• Scrap reduction
• Rework elimination
• Process optimization
• Energy efficiency
• Cycle time improvement
• Identify and implement value engineering initiatives.
• Establish a culture of cost ownership across all operational functions.

Commercial Leadership

• Work closely with Commercial and Sales teams to improve plant profitability.
• Support pricing negotiations with domestic and international customers.
• Identify margin-dilutive products, contracts, and customer accounts.
• Participate in strategic customer discussions while maintaining long-term relationships.
• Ensure commercial commitments align with manufacturing capabilities and cost structures.

Leadership & Stakeholder Management

• Provide regular updates to senior leadership on turnaround progress and business performance.
• Build strong working relationships with the Production Head and cross-functional teams.
• Maintain customer confidence during the transformation period.
• Lead organizational change and foster a culture of accountability and continuous improvement.

Capability Building

• Develop sustainable processes and systems to ensure long-term operational excellence.
• Coach and mentor the Production Head and plant leadership team.
• Document best practices and establish standardized operating procedures.
• Build organizational capability to sustain performance improvements beyond the transformation phase.

Required Qualifications

• Bachelor's Degree (B.E./B.Tech) in Mechanical, Production, Industrial Engineering, or a related discipline.
• MBA or equivalent management qualification is preferred.

Experience

• 20–25 years of progressive experience in manufacturing operations.
• Demonstrated success in leading plant turnarounds or large-scale operational transformation initiatives.
• Strong background in:
• Automotive Components
• Precision Engineering
• Transmission Systems
• Commercial Vehicle Components
• Heavy Engineering Manufacturing
• Experience managing export-oriented manufacturing operations.
• Proven track record of delivering measurable improvements in:
• Cost reduction
• Productivity
• Quality
• Operational excellence
• Experience collaborating with commercial teams on customer negotiations and profitability improvement initiatives.

Technical Competencies

• Plant Operations Management
• Lean Manufacturing
• Total Productive Maintenance (TPM)
• Theory of Constraints (TOC)
• Manufacturing Excellence
• Overall Equipment Effectiveness (OEE)
• Capacity Planning
• Production Planning & Control
• Manufacturing Cost Analysis
• Quality Management Systems
• Customer PPM Reduction
• Root Cause Analysis
• Value Engineering
• Export Manufacturing
• Commercial Acumen
• Plant P&L Management

Leadership Competencies

• Strategic Leadership
• Operational Transformation
• Structured Problem Solving
• Data-Driven Decision Making
• Change Management
• Stakeholder Management
• Cross-functional Leadership
• Team Development & Coaching
• Customer Relationship Management
• Commercial Negotiation
• High Accountability
• Integrity and Ownership
• Results Orientation

Key Performance Indicators (KPIs)

Performance will be measured against agreed business objectives, including:

• Improvement in plant profitability (EBITDA)
• Manufacturing cost reduction
• Capacity utilization improvement
• Overall Equipment Effectiveness (OEE)
• Customer PPM reduction
• TPM implementation maturity
• Scrap and rework reduction
• Equipment reliability improvement
• On-time customer delivery performance
• Commercial improvement of loss-making contracts
• Development of a self-sustaining, high-performing plant leadership team